CONTAINER FOR LIQUIDS

Abstract: A container (10) for transporting and storing a liquid comprising an outer container; an inner liner (20) and a top closure film (30), both inner liner and top closure being films comprising at least one plastic layer (23, 33) and an impermeable layer (22, 32) and a sealant (50) disposed above the level of contained liquid and between the juncture of the inner liner and top film. The inner liner and top closure are preferably laminate films having an inner air impermeable (for example, metal foil) layer (22, 32) between a first plastic (for example, polyester) layer (23, 33) and a second plastic (for example, polyethylene) layer (21, 31).

Description: CONTAINER FOR LIQUIDS This invention relates to a container, particularly a container for shipping liquids and to a method for protecting a liquid from the environment during shipping. Many liquid resin or adhesive systems such as moisture curaDle polyurethane polymers (for example, sealant primers) or polyurethane prepolymers solidify or cure upon exposure to air or moisture Therefore, it is desirable to minimize contact between these liquids and the environment prior to their end-use application. While exposure to the environment is more or less of a problem depending on the liquid resin or adhesive system employed, the problems associated with premature contact with the environment are aggravated by long periods between preparation of the liquid resin or adhesive and its actual use This is a particular problem when the liquid resin or adhesive is shipped over long distances or is maintained in the shipping container for long periods of time prior to use. In a conventional operation, the liquid resin or adhesive is placed in a metal drum, commonly a 55 gallon or larger drum, often iined with a plastic film adhered to the inner metal layer to prevent corrosion and contamination of both the drum and the liquid. The drum is covered with a metal or plastic coated metal top having approximately the same size as the drum body which is locked to the drum using a locking collar or bung. The means for securing the metal lid or top to the drum body is not particularly effective in preventing the contact of the environment with the drum contents. As such, portions of the liquid resin or adhesive solidify or cure and, upon removal, the solid or cured material is removed with the liquid; thereby introducing impurities into the finished article. It is also necessary to clean the drum after each use. In addition, disposing the metal drum results in both economic loss and environmental damage. A filler of a fusible plastic such as polyethylene is often placed in the drum to contain the liquid resin or adhesive and the fusible plastic is then sealed such as by heating or by merely using a tie (see, for example, U.S. Patent No. 3,940,052). This provides a more effective barrier between the environment and the contained liquid, but when stored for long periods of time or shipped over long distances the barrier is not suitable for many applications. in addition, the loose plastic fillers are not easily handled. Yet another method for shipping a liquid resin or adhesive involves disposing an inner liner of a plastic material having the general shape of the drum which is commonly a paperboard or fiberboard drum against the walls and top of the drum, gluing or otherwise adhering the plastic to the interior surface of the drum (see, for example European Patent Application No. 0 501 015) Alternatively, U.S. Patent No. 4,347,948 teacnes a container in which a plastic inner l i ner is employed which extends beyond the top of the drum A typical inner l iner consists of an elastic plastic film, incl udi ng thermoplastic plastic sucn as polyethylene, polypropylene, polyester, or nylon as well as compound films sucn as the plastic with another material (for example, paper, cloth or metal foi l) lami nate havi ng layers of polyethylene, metal foil and polyester with the polyethylene layer being closest to and bonded to the interior surface of the drum The cover or lid comprises a body, a plastic sheet and a ring packing so as to make it possi ble to seal the container body to be ai r-tight These contai ners do not eli minate the problems associated with premature curing or solidification Alternatively, a drum having a plastic inner nner (for example, a laminate of plastic and metal foil) extending beyond the top of the drum is filled with the liquid to be stored or shipped Once filled, a plastic (for example, polyethylene) fi lm, larger than the opening in the drum, is placed over the top of the liquid and the drum sealed using a metal or paper top or lid placed over the polyethylene fil m The excess portions of the top fi l m and inner liner contact each other above the l iquid layer to seal the contai ner The problems associated with premature curing or solidification, while reduced, are not eliminated Uoon shipping or storage, the liquid near the seal can solidify or cure, with cured or solidified l umps or droplets contained in the bulk of the liquid material In view of the stated deficiencies of the prior art, it remains desirable to provide a container for liquid resins and adhesives which reduces or minimizes contact of the resin or adhesive with the drum and the environment (air and moisture) during shipping or storage Such a container which facilitates easy reuse of the outer drum without complex cleaning steps is desirable Accordingly, in one aspect, the present invention is a container comprising a form providing structure defi ning an enclosed cavity of predetermined shape and having an opening, an inner liner of a film comprising at least one plastic layer and an impermeable layer, which inner liner conforms generally to the predetermined shape of the structure, a top closure film comprising at least one plastic layer and an impermeable layer, the top closure layer having a size such that a plastic layer of the top closure film and a Dlastic layer of the inner liner can be placed in inti mate contact with each other, and a sealant disposed between the juncture of the inner nner and top laminate films and means for introducing a liquid into the container Accordingly, in another aspect, the present invention is a container filled with liquid comprising a form providing structure defining an enclosed cavity of predetermined shape and havi ng an opening, an inner nner of a turn comDπsing at least one plastic layer and an impermeaDie layer wnich i nner n ner contorms general ly to the predetermined shape of the structure l iquid fi ll i ng at least a portion of the l ined structure such that a portion of the i nner liner extends beyond the liquid contained by the structure above the contained liquid, a top closure film comprising at least one plastic layer and an impermeable laye r , the top closure layer having a size such that a plastic layer of the top closure film and a plastic layer of the i nner l iner can be placed in intimate contact with each other; and a sealant disposed above the level of contained liquid and between the juncture of the i nner li ner and top laminate films In a preferred embodi ment, the present invention is a container fil led with liquid comprising a form providing structure defi ning an enclosed cavity of predetermi ned shape and having a fill opening; an inner liner of a laminate film comprising an imoermeable layer between a layer of polyester, and a layer of polyethylene, which inner liner conforms generally to the shape of the structure and is positioned in the cavity so that the polyethylene layer is closest to the inner surface of the structure, liquid filling at least a portion of the lined structure such that a portion of the inner liner extends beyond the liquid contained by the structure; a top laminate closure film comprising an impermeable layer between a layer of polyester and a layer of polyethylene placed on the surface of the liquid with the polyester layer being closest to the liquid and having a size such that at least a portion of the top laminate film overlaps the contained liquid such that the polyester layer of the inner liner and the polyester of the top film are in intimate contact with each other; and a sealant disposed above the level of contained liquid and between the juncture of the inner liner and top laminate films In a particularly preferred embodi ment, the sealant is a moisture curable adhesive such as a polyurethane prepolymer of an isocyanate and a material which catalyzes or promotes the reaction between an isocyanate and water A barrier such as a cured sealant further prevents the exposure of the contained liquid to the environment The containers of the present invention effectively reduce the amounts of air or moisture to which the liquid is exposed upon shipping or long storage As such, the liquid resin or adhesive is less susceptible to solidification or curing; thereby facilitating end-use application of the liquid The containers are particularly useful in snipping or storing moisture curable polyurethane compositions Understanding of this invention will be facilitated by reference to the accompanying drawings, in which Figure 1 is a cross-sectional schematic representation of an embodiment of this i nvention; and Figure 2 is a cross-sectional schematic of the juncture between the i nner li ner and the fi lm l id il l ustrati ng a preferred embodiment usi ng an i mpermeable sealant Referring now more particularly to the drawings, Figure 1 which reoresents an embodiment of this i nventi on 1 depicts a form providi ng structure 10 The structure is shown i n 5 the ill ustrated embodiment as a container 10 havi ng wall 12 and base 13, but the form providing structure can take essential ly any shape Within the cavity 1 1 formed by structure 10 and conformi ng general ly to its shape is an inner liner 20 Inner l iner 20 can be prepared having a base such as descri bed in U S Patent No 3,940,052 or having a base portion which is thicker than its side portions such as described in U S Patent Mo 4,347,948 Inner l i ner 20 10 extends beyond the liquid level 40 in structure 10 and preferably beyond the wal ls 12 In the depicted embodiment, inner liner 20 is a laminate comprising at least three layers a plastic (preferably, polyethylene) layer 21 , a layer of a gas impermeable layer such as a metal foil 22, and a second plastic (preferably, polyester) layer 23 In the illustrated embodi ment, the polyethylene layer is disposed closest to the inner surface of the structure and is preferably 1 5 glued or bonded to the interior surface of structure 10 The glue or bonding is preferably sufficient to maintain the inner liner i n intimate contact with the container during the fil l ing of the container cavity with liquid and shipping, but which allows the inner liner to oe removed for discarding after use Conventional techniques for applying the inner li ner to the container are suitably employed 20 The liquid 40 fills a portion of cavity 1 1 In the illustrated embodiment, a top closure film 30 covers the liquid 40 in cavity 1 1 and extends beyond the opening i n container 10 In the illustrated embodiment, film 30 is a laminate comprising a layer of plastic (preferably polyester) 33, a layer of a gas impermeable layer such as a metal foil 32, and a second layer of plastic (preferably, polyethylene) 31 placed on the surface of the liquid with the polyester layer 25 33 being adjacent to the liquid In the embodiment depicted in Figure 1 , the portion of top closure film 30 which extends beyond the diameter of container 10 is disposed adjacent to the portion of the inner l iner 20 which extends above the level of liquid contai ned by contai ner 10 In such a manner, the polyester layer 23 of inner liner 20 and polyester layer 33 of the top film 30 lie adjacent each other 30 As shown more clearly in Figure 2, between the polyester layer 23 of inner li ner 20 and polyester layer 33 of the top lami nate film 30 is disposed a sealant 50 While the adjacent polyester layers in the inner liner 20 and top laminate film 40 reduce the contact of the contained liquid with the environment, the sealant 50 further reduces contact between the environment and liquid and is selected accordingly In general, sealant 50 is a liquid material 35 which wnen exposed to air, moisture, or slightly elevated temperatures wi l l cure or solidify and bond the inner and too laminate fi lms to one another while providing increased protection to the αuid in the container as opposed to IT no sealant is employed Alternatively, the seai ant is ' ess preτeraoιy a pliable or malleable solid material having suitaole impermeaomtv properti es In constructi ng the container after the l iquid is placed in the contai ner cavity and the top laminate fi l m placed on the surface of the l iquid, the sealant, i n l iquid form, is placed on the polyester layer 23 of inner film 20 ano/or the polyester layer 33 of too film 30, preferably both, and the two fil ms pressed together unti l the sealant is secured into place such as by curing In general, it is preferred if the sealant wi l l cure within a few seconds to sufficiently bond the i nner and top lami nate layers such that further pressure is no longer requi red to mai ntain the two layers in position An additional cover or lid 60 such as a metal or paperboard lid can be and is preferably placed over top fil m 30 for structural purposes and to prevent damage during shipping and storage For ease in dispensing the l iquid when desired, it is also often advantageous to put a smaller dispensing port such as described in European Patent Appl ication No 0 501 01 5 i n the top laminate fi lm 30 and, if employed, the additional cover, so that the contained l iquid can be dispensed through the smal ler port without removal of the larger cover or top lami nate film such as by means of a dip leg Preferably, the smal ler port is easily removed when it is desirable to dispense the liquid from the container In the embodiment where the sealant at the juncture of the inner liner and the top closure film is cured prior to filling some means of introducing a liquid into the container is required This can be a port which can later be used to remove the liquid Alternatively, it can be an opening in the top closure film which is sealed after filling Filli ng can be performed using means well-known in the art Preferably, the container with the inner liner fi lm in place is filled pπor to putting the top closure film and sealant in place In another embodiment the container can be assembled, the sealant for the inner and top laminate film can be contacted and the sealant cured prior to filling of the drum In such embodiment, the liquid contents can be added to the container through a filli ng port in the top laminate fi lm or the container can be filled from the bottom by inserting an appropriate filling apparatus through a port i n the top of the laminate film With regards to the various components employed i n the present invention, the form providing structure can take almost any form and size and be made from essentially any material provided that the structure provides a cavity to contain the liquid and the material provides sufficient structural integrity during shipping and storage to prevent damage and loss of the contained liquid In general , the form providing structure is advantageously a conventional container for sni pping liquids sucn as a metal , fiber, paperboard, plastic container, for example, a 40 to 60 gallon drum or smal ler pai l such as a five gallon metal pai l or bucket, or a cartridge such as a caulking gun cartridge although larger as well as smal ler capacity containers can be employed dependi ng on the amount of liquid to be snipped ano/or stored Both the inner liner and too laminate films are preferably laminated films comprising a polyethylene layer, a gas impermeable layer, and a polyester layer If the impermeable layer is a metal foi l , an adhesive is general ly used to assist i n bonding the gas impermeable layer to the polyethylene layer and an adhesive or polymeric film (for example, l inear low density polyethylene) is employed to bond the metal foil to the polyester layer Yet additional fil m or adhesive layers are not proscribed By the term "polyethylene fil m layer" is meant a fi lm made from a polymer or copolymer of ethylene, that is, a polymer derived solely from ethylene or ethylene and one or more monomers copolymeπzable therewith Such polymers (i ncluding raw materials, thei r proportions, polymerization temperatures, catalysts and other conditions) are well-known i n the art and reference is made thereto for the purpose of this invention Additional comonomers which can be polymerized with ethylene include α-olefin monomers havi ng from 3 to 12 carbon atoms, α,β-ethylenιcal iy unsaturated carboxylic acids (both mono- and difunctional) and derivatives of such acids such as esters (for example, alkyl acrylates) and anhydrides, monovinylidene aromatics and monovinylidene aromatics substituted with a moiety other than halogen such as styrene and methylstyrene, and carbon monoxide Exemplary monomers which can be polymerized with ethylene include 1 -octene, acrylic acid, methacrylic acid, vinyl acetate and maleic anhydride The ethylene polymers advantageously comprise at least about 50 weight percent ethylene, with the preferred ethylene polymers comprising at least about 75 weight percent ethylene and the more preferred ethylene polymers comprisi ng at least about 90 weight percent ethylene The preferred ethylene polymers include low density polyethylene, high density polyethylene, linear low density polyethylene (a copolymer of ethylene and up to about 20 weight percent of one or more additional α-olefins having from 3 to 12 carbon atoms, preferably from 4 to 10 carbon atoms, more preferably from 4 to 8 carbon atoms In general, high density polyethylene and linear low density polyethylene are particularly useful in the practice of the present invention, and, to a lesser extent, due to its higher branching, low density polyethylene The present invention is also useful for blends of two or more ethylene polymers Suitable methods for the preparation of high density polyethylene, low density polyethylene, and linear low density polyethylene polymers are well-known in the art and reference is made thereto for tne purposes of this i nvention Linear low density polyethylene (LLDPE) is conventionally a copolymer of ethylene and an α-olefin having four or more carbon atoms, preferably from 5 to 10 carbon atoms LLDPE generally comprises a structure which is intermediate between the long linear chains oτ HDPE and the nighiy brancned cnains of LDPE The density of LLDPE generally var.es from 0 91 to 0 94 grams per cubic centi meter (ASTM D 792) Ill ustrative techniαues for the preparation of LLDPE are described i n U S Patent Nos 2,825,721 , 2,993,876, 3,250,825, ana 4,204,050 As described in these references, in general, LLDPE is prepared by polymerizing a mixture of the desired types and amounts oτ monomers in the presence of a catalytically effective amount (normally from 0 01 to 10 weight percent based on the weight of the ethylene being polymerized) of a coordination catalyst such as described in U K Patent 1 ,500,873 In general, the polymerization is conducted at relatively low pressures (for example, from 5 to 40, preferably from 5 to 15, atmospheres) and temperatures from 0" to 300 C, more preferably from 60° to 160"C Preferred linear low density polyethylenes include copolymers of ethylene with 1 - octene, 4-methyl-1-pentene, 1 -hexene, or 1 -butene, preferably 1 -octene Preferably, the LLDPE copolymers are a copolymer comprising, in polymerized form, from 99 5 to 65, more preferably from 99 to 28, weight percent ethylene and from 0 5 to 35, more preferably from 1 to 20, weight percent of the higher α-olefin Most preferably, the LLDPE copolymers comprise from 98 to 85 weignt percent 1 -octene or 4-methyl-1 -pentene, most preferably 1-octene, said weight percents being based on the total weight of the ethylene and 1 -octene, 1-hexene, 1 -butene, or 4-methy-1 -pentene in the resulting copolymer In general, high density polyethylene (HDPE) has a density of at least about 0 94 grams per cubic centimeter (g/cc) (ASTM Test Method D 1505) HDPE is commonly produced using techniques similar to the preparation of linear low density polyethylene When HDPE is employed in the practice of the present invention, it preferably has a density from 0 96 to 0 99 g/cc and a melt index from 0 01 to 35 grams per 10 minutes as determined by ASTM Test Method D 1238 Low density polyethylene ("LDPE") is generally comprised of highly branched chains with a density of less than about 0 94, generally from 0 91 to 0 94, grams per cubic centimeter (g/cc) (ASTM D 792) Illustrative of techniques for preparing LDPE are described in U S Patent Nos 3,756,996 and 3,628,918 As described therein, LDPE is conventionally prepared in the presence of a catalytic effective amount of a free radical initiator, for example, a peroxide such as di-tert-butyl peroxide or tert-butylperacetate in amounts from 0 1 to 2 weight percent based on the weight of the monomers In addition, small amounts of oxygen, for example, from 1 to 100 weight parts per one million parts of monomer are generally advantageously employed in the polymerization Typically, the polymerization is conducted at relatively high pressures (for example, from 100 to 3000 atmospheres ( 1 01 x 10' Pa to 3 04 x 10" Pa)) and temperatures (from 50^C to 350°C) In general, pressures from 1000 to 2000 atmospheres (1 01 x 10' Pa to 2 02 x 10' Pa) and temperatures from 100°C to 300°C are more typically employed The polyethylene layer in the closure or top laminate film is preferably heat- sealable and is more preterably an essentially pinnole free or pinhole free, low density, heat- sealable polyethylene The polyethylene in the inner liner is preferably linear low density polyethylene The gas impermeable layer is a film layer prepared from a material wnich is suitably impermeable to air or the environment for the intended purpose While the permeability properties of such layer may vary depending on the liquid employed and its susceptibility to moisture or the environment as well as the thickness ana specific composition of the polyethylene and polyester film layers, in general, the material employed in preparing the impermeable film layer is a material such that the inner liner and top laminate film have a gas transmission of less than about 0 5, preferably less than 0 2, more preferably less than 0 15, cubic centimeters (cc) per 100 square inches (254 square centimeters) in a 24 hour period (ASTM-1434) Most preferably, the gas permeability is less than about 0 1 cc/100ιn 2 24 hours (0 1cc/254cnV24 hours) In addition, the barrier layer is prepared from a material which is compatible or which can be made compatible with the polyethylene and polyester layers, that is, the gas impermeable barrier layer can be prepared as a laminate with the polyethylene and polyester layers, such as using an adhesive between one or more of the layers (for example, the aluminum foil and low density polyethylene) or by coextruding a polyethylene layer between the polyesterand metal foil layer While certain polymers such as vinyl chloride polymers can be employed as the barrier layer, in general, a metal foil or metalized polymer film is most advantageously employed as the impermeable layer A preferred metal for use as the impermeable layer is aluminum, more preferably an essentially pinhole free or pinhole free, dead-soft, aluminum foil The polyester layer is a film made from a polyester material Polyesters and methods for their preparation (including the specific monomers employed in their formation, their proportions, polymerization temperatures, catalysts and other conditions are well-known in the art and reference is made thereto for the purposes of this invention For purposes of illustration and not limitation, reference is particularly made to pages 1-62 of Volume 12 of the Encyclopedia of Polymer Science and Engineering, 1988 revision, John Wiley & Sons Typically, polyesters are derived from the reaction of a di- or polycarboxy c acid with a di- or poiyhydπc alcohol Suitable di- or polycarboxyhc acids include saturated polycarboxyhc acids and the esters and anhydrides of such acids, and mixture thereof Representative saturated carboxylic acids include phtha c, isophtha c, adipic azelaic, tereohthahc, oxalic, malonic, succinic, glutaπc and sebacic Dicarboxylic components are preferred Terephtha c acid is most commonly employed and preterred in the preparation of polyester films α,β-unsaturated di- and polycarboxyhc acids (including esters or anhydrides of such acids and mixtures thereof) can be used as partial replacement for the saturated carboxylic components Representative α.β-unsaturated di- ano ooiycarooxyiic aciαs include maleic, fumaπc, aconitic, itaconic, mesaconic, citraconic and monocnloromaleic Typical di- and polyhydric alcohols used to prepare the polyester are those alcohols having at least two hydroxy groups, although mi nor amounts of alcohol having more or less hydroxy groups may be used Di hydroxy alcohols are preferred Dihydroxy alcohols conventionally employed in the preparation of polyesters incl ude diethylene glycol , dipropylene glycol , ethylene glycol , 1 ,2-propylene glycol , 1 ,4-butanedιol , 1 ,4pentanedιol and 1 ,5-hexanedιol with 1 ,2-propylene glycol being preferred Mixtures of the alcohols can also be employed The di- or polyhydric alcohol component of the polyester is usual ly stoichiometric or in slight excess with respect to the acid The excess of the di- or polyhydric alcohol wil l seldom exceed 20 to 25 mole percent and usual ly is between 2 and 10 mole percent The polyester is generally prepared by heating a mixture of the di- or polyhydric alcohol and the di- or polycarboxyhc component in their proper molar ratios at elevated temperatures, usually between 100 c C and 250°C for extended periods of time, general ly ranging from 5 to 1 5 hours Polymerization inhi bitors such as t-butylcatechol may advantageously be used The polyester film is preferably a biaxial ly oriented, pinhole free polyester film Metahzed polymer films comprise a plastic film having a thin metal deposited on a surface The metal layer is generally deposited on the film surface as a metal vaoor layer in a vacuum A preferred metal is aluminum Preferred plastic film comprises polyethers, polycarbonates, nylons and polypropylene The preferred films comprise polyesters The thickness of the top and inner film layers as well as each layer (that is, the polyethylene layer, the polyester layer and the barrier layer) i n the laminate are dependent on a number of factors including the liquid being shipped or stored i n the container, the length of shipping and storage prior to use, and the specific composition employed in each layer of the laminate In general , the inner liner will have a total thickness of from 7 to 2000, preferably from 25 to 500 μm, with the thickness of the polyethylene layer being from 5 to 750, preferably from 10 to 300 μm , the thickness of the polyester layer being from 1 to 250, preferably from 5 to 100 μm and the thickness of the barrier layer being from 1 to 100, preferably from 5 to 50 μm when the barrier layer is a metal foil In general , the top laminate fi lm wil l have a total thickness of from 16 to 1000, preferably from 20 to 250 micron (μm), with the thickness of the polyethylene layer being from 10 to 500, preferably from 25 to 200 μm; the thickness of the polyester layer being from 5 to 200, preferably from 15 to 100 μm , and the thickness of the barrier layer oeing from 1 to 100, preferably from 5 to 50 μm when the barrier layer is a metal foil Both the inner and the top laminate layers can be prepared by tecnniques wel l- κnown i n the art for the preparation of ti lm laminates and reference is made thereto for the purposes of this invention The sealant is employed to decrease the Dermeaoihty at the j uncture between the inner liner and the top laminate film In general, any material which reduces permeability of the envi ronment and which sufficiently acts to glue the i nner and top lami nate layers to one another can be employed and selection of the material which is most advantageous will be dependent on a variety of factors incl uding the contai ned liquid and its susceptibility to moisture and/or air, the specific inner and top laminate layers employed, and the expected duration of shipping and storage Representative examples of materials which can be employed as the sealant incl ude hot melt adhesive such as hot melt adhesives based on polyester, polyamides or block copolymer rubbers, adhesives which are applied from solution or dispersion such as phenohcs and ammo resins which can be appl ied from water solution, or acrylics or polyurethanes which can be applied from organic solutions, or epoxies applied from aqueous dispersion An adhesive which can be applied dry and then activated such as by exposure to water or an organic solvent can also be employed In addition, pressure sensitive adhesives can also be employed Preferred sealants are those materials which have good shelf l ife in the absence of air or moisture but which cure rapidly upon exposure to moisture or ai r Particularly preferred adhesives are moisture curable polyurethanes such as described in U S Patent Nos 4,758,648, 4,780,520, and 5,086, 1 51 These sealants comprise a polyurethane prepolymer (an isocyanate-terminated reaction product of an organic polyisocyanate with a polyhydroxy compound, preferably having an isocyanate functional ity of between 2 3 and 3 0) and a catalyst useful for promoting the reaction of isocyanate groups with water Of the described polyurethane prepolymers, the prepolymers prepared by reacting a stoichiometric excess of a dnsocyanate such as dιphenylmethane-4,4'-dnsocyanate with a mixture of a diol such as polyoxypropylene diol and a tπol such as polyoxypropylene tπol are particularly preferred A catalyst such as stannous chloride is commonly employed in such reaction Preferred compositions comprise a polyurethane prepolymer having an isocyanate functionality of between 2 3 and 3 0 and from 0 2 to 1 75 weight percent of dimorphohnodiethyl and a polyurethane prepolymer having from 0 2 to 2 weight percent of a dι [2-(3,5-dιmethylmorpholιno)-ethyl] ether catalyst These materials are particularly useful since they oond to the polyester films on both the inner and the top laminate fil ms thereby effectively seal ing the liquid from the environment Using these preferred moisture curable adhesives as the sealant and in other appropriate cases, the sealant can be the same as the l iquid being stored or shi pped In such case, prior to filling the container, the top laminate film is put in place and the container filled from the bottom Uoon completion of fil li ng, the impermeable sealant is cured by its exposure to air, tnereby gluing the top lami nate and i nner liner together to produce an air impermeable seal Alternatively, the seaiant comDOSition is applied to either or both the polyester laver of the inner and too lami nate films arter ti l li ng the contaι ne r at wnicn time the τι ms are giued together and the seaiant, being exposed to moisture, bonds the films. In general, once applied from the moisture-free environment onto the inner and/or top laminate film, the seaiant will effectively cure within 30 seconds to 300 minutes, advantageously from 1 to 30 minutes.

Claims: CLAIMS 1 A container ^i lled with liquid comprising a τorm providing structure defi ni ng an enclosed cavity of predetermined shape and having an opening, an inner liner of a film comprising at least one plastic layer and an i mpermeable layer, which inner li ner conforms general ly to the predetermined shape of the structure, liquid filling at least a portion of the lined structure such that a portion of the inner i iner extends beyond the liquid contained by the structure, a top closure fi lm comprising at least one plastic layer and an impermeable layer, the top closure layer having a size such that a plastic layer of the top closure film and a plastic layer of the inner li ner can be placed i n intimate contact with each other above the contained liquid , and a sealant disposed above the level of contained liquid and between the j uncture of the inner l iner and top laminate fil ms 2 The container of Claim 1 wherein the sealant is a moisture curable polyurethane 3 The container of Clai m 2 wherei n the sealant is a polyurethane prepolymer having an isocyanate functionality of between 2 3 and 3 0 and from 0 2 to 1 75 weight percent of dimorpho nodiethyl 4 A container filled with liquid comprising a form providing structure defining an enclosed cavity of predetermined shape and having a fill opening, an inner liner of a laminate film comprising an impermeable layer between a layer of polyester and a layer of polyethylene, which inner liner conforms generally to the shape of the structure and is positioned in the cavity so that the polyethylene layer is closest to the inner surface of the structure, liquid fil ling at least a portion of the lined structure such that a portion of the inner l iner extends beyond the liquid contai ned by the structure, a top laminate closure film comprising an impermeable layer between a layer of polyester and a layer of polyethylene placed on the surface of the liquid with the polyester layer being closest to the liquid and having a size such that at least a portion of the top laminate film overlaps the contained liquid such that the polyester layer of the inner liner and the polyester of the top fi lm are i n i ntimate contact with each other above the contained liquid; and a sealant disposed above the level of contained liquid and between the juncture of the i nner nner and top lami nate films 5 The contai ner ot Clai m 4 wherei n tne sealant is a moisture curable ooivurethane • ' 2- 6. The container of Claim 4 wnerein the sealant is a composition of a polyurethane prepolymer having an isocyanate functionality of oetween 2.3 and 3 0 and having from 0.2 to 1 75 weight percent of dimorpholinodiethyl or a composition of a polyurethane prepolymer having from 0 2 to 2 weight percent of a dι[2-(3,5- dιmethylmorphohno)ethyl] ether catalyst 7 The container of Claim 4 wherein the inner liner has a total thickness of from 7 to 2000 micron, with the thickness of the polyethylene layer being from 5 to 750, the thickness of the polyester layer being from 1 to 250, and the thickness of the barrier layer being from 1 to 100 micron 10 8 The container of Claim 4 wherein the top laminate film has a total thickness of from 16 to 1000 micron, with the thickness of the polyethylene layer being from 10 to 500, the thickness of the polyester layer being from 5 to 200, and the thickness of the barrier layer being from 1 to 100 micron. 9. The container of Claim 4 wherein the inner liner has a total thickness of from 15 25 to 500 micron, with the thickness of the polyethylene layer being from 10 to 300, the thickness of the polyester layer being from 5 to 100, and the thickness of the barrier layer being from 5 to 50 micron and the top laminate film has a total thickness of from 20 to 250 micron, with the thickness of the polyethylene layer being from 15 to 200, the thickness of the polyester layer being from 10 to 100, and the thickness of the barrier layer being from 5 to 50 o micron. 10 A container comprising: a form providing structure defining an enclosed cavity of predetermined shape and having an opening; an inner liner of a film comprising at least one plastic layer and an impermeable 25 layer, which inner liner conforms generally to the predetermined shape of the structure; a top closure film comprising at least one plastic layer and an impermeable layer, the top closure layer having a size such that a plastic layer of the top closure film and a plastic layer of the inner liner can be placed in intimate contact with each other; and a sealant disposed between the juncture of the inner liner and top laminate films 30 and means for introducing a liquid into the container. 35

Inventors: PARADINE JOHN E, PARADINE, JOHN, E.
Applicants: ESSEX SPECIALTY PROD, ESSEX SPECIALTY PRODUCTS, INC.
Application year: 1994
Main classification: B65D25
IPC codes: B65D25, B65D88, B65D90